996 Water Pump Gotcha

[Funracer]

Many good water pump replacement videos out there. I watched them all and not one tutorial mentioned what happened to me and many others per Google. Lots of suggested fixes but no one confirmed how they were able to get it done afterwards.

This DIY requires you to support the engine with a jack, then remove the exhaust bracket, the exhaust bracket bracket (?) and then loosen the engine carrier nuts in order to slide the carrier rearward about 1/4 inch which is enough to get the WP out.

This is the area I and others have had an issue:


All went well new WP and thermostat installed. On reassembly the alignment bolt for the carrier bracket would not thread:

Not only was the threaded port too low, but also off center right. So raising the engine with the jack would raise the threads up but they were still off center.

No amount of loosening or tightening the carrier nuts, or lifting or lowering the engine with jack or tapping the carrier around would align the holes enough to start the “carrier alignment bolt” such that I could hand start it. After another 3 hours I loosened the engine mount nuts (18mm). No help. Frustrated, gave up for the day.

Next morning back at it finally figured out the fix. Super easy but I never saw anyone mention it so for anyone searching in the future here goes.

It was my thought that the jack is used to support or raise the engine as needed. You must use the jack to raise the engine, but moving the jack around the oil sump will also move the motor left /right. If I move the jack (with 2x4) left on the sump it would pull the engine left or move it right it would pull engine right. Thus you can raise/lower or left/right the threads until it all lines up:


Knowing this would have saved me many hours of frustration. There is even a thread online that shows a car where the PO had left this bolt out because he could not get things lined up.

WP and thermostat not a hard job. If your have alignment bolt issues now you know the fix!

[bigel]

Man...glad you got it figured out.

Thanks for adding to the general information/self-help aspects of the thread...never cease to be amazed by the P-Car community and the depth of knowledge of the membership.

Can you provide a bit more of an explanation of what you mean by "moving the jack around the oil sump"? Do you mean that you lowered the jack, maybe using jack stands to support the engine, and then re-positioned the jack and 2x4 to a location slightly left or right, or that you moved the jack while under load?

Sorry, I'm just not able to envision what you're describing.

Thanks in advance.

[Funracer]

Lowered the jack and moved it. There are a few DIY videos that have you remove the carrier completely. In that case you would not be able to move the jack around.

Most of them, including the PP DIY, only loosen the carrier plate nuts (do not remove them) enough to pull the plate backwards just a bit. The carrier is still in place on the engine studs with nuts on loosely, and the engine mounts are still attached and supporting the engine while you move the jack.

[bigel]

Ah...got it.

Thanks again for the post.